Distributor Documents - Ace Manufacturing

300 Ramsey Street

Sullivan, MO 63080

Ph. (573)468-4181

Fax (573)468-5584

Website: Ace-Mfg.com

AMERICAN MADE SINCE 1967

• 14 inch and 15½ inch - Medium and Heavy Duty Clutches

• Flywheels for Caterpillar, Cummins, Detroit, Ford, Mack, Navistar

• Clutch Accessories

• Warranty

• Technical Assistance

“An Innovative leader in clutch tgechonology”

1. Release Bearing and Sleeve Assembly a. Release bearing centered in housing b. Forks pull on housing to release clutch sleeve c. Sleeve connects release bearing to retainer by snap ring and half locks d. Sleeve has 2 brass bushings pressed and indented e. Requires routine maintenance 2. Cover Assembly a. 6 Spring standard pedal b. 9 Spring EZ Pedal c. Houses all internal clutch parts d. Often referred to as pressure plate 3. Adjusting Ring a. Threads into cover assembly b. Has 6 lever saddles c. Repositions levers when adjusting clutch for proper plate load and release to compensate for wear 4. Pressure Springs a. Springs put pressure on retainer to achieve proper plate load for unit b. Units have 6 pressure springs with total plate loads ranging from 2400 to 4000 lbs. c. Located between retainer and cover assembly 5. Assist Springs a. 3 Springs located between retainer and cover to assist in pedal effort when releasing clutch b. EZ Pedal only 6. Spring Pivots a. Fits over machined surfaces on retainer and cover assembly for smooth spring action and to reduce wear 7. Retainer a. All internal clutch components connect to retainer to release the clutch b. The retainer is pulled, compressing pressure springs and pivoting levers allowing pressure to be removed from pressure plate, thus allowing the clutch release 8. Thrust Washer, Half Locks, Snap Ring a. Method of connecting sleeve and bearing assembly to retainer 9. Included above 10. Included above 11. Levers a. 6 levers per unit located between retainer and saddles on adjusting ring b. Apply or remove pressure from pressure plate by pivoting on the fulcrum of the pressure plate 12. Pressure Plate a. Applies clamping force from cover assembly to discs and center plate against flywheel b. Plate is held in place by straps bolted to plate and riveted to cover 13. Clutch Discs a. Drives the input shaft through a splined hub transferring d. Dampens with 7, 8, 9, 10 dampening springs b. Buttons refer to friction material looking like pads, pucks, or buttons e. Have 3, 4, or 6 sets of buttons c. Can have non-asbestos organic facing f. Clutches can have dual or single discs 14. Intermediate Plate a. Used on dual disc clutch, adds friction surface to increase torque while absorbing heat b. The intermediate plate fits in cover assembly with lugs machined on plate and slots corresponding in cover

3

1

2 4

3

5

6

7

8-10

11

14

13

12

13

15.5 EZ Rider Assembly

1-800-325-6138 05/01/11

Part Number Reference Description Price

A119BP 274C-6 Drive Pin 14" Flywheel (6 per card) $6.95A148BP 2" Brake Spacer (6 per card) $5.36A153BP 1.75" Brake Spacer (6 per card) $6.98A230EZ E-Z Adjuster $9.95A236BP Spring Loaded Adjuster $13.25A237BP N/A 2" 1pc Clutch Brake $6.36A238BP N/A 1.75" 1pc Clutch Brake $6.36A239BP 127740 1.75" Torque Limiting Brake $14.69A240BP 127760 2" Torque Limiting Brake $14.69B175 1.75" 2 pc Hinge Clutch Brake $15.50B201 N/A 2" 2pc Hinge Clutch Brake $15.50B201-500 2" Oversized 2 pc Hinge Clutch Brake $16.50A537BP 127200 2" 2pc Clutch Brake $17.14A538BP 127175 1.75" 2pc Clutch Brake $17.14AB195BP 6205-2RS Pilot Bearing (rubber sealed) $2.59AB195SBP 6205-2RSNR Pilot Bearing (rubber sealed for Mack) $3.53AB197BP 6306-2RS Pilot Bearing (rubber sealed for Mack) $4.07AB197SBP 6306-2RSNR Pilot Bearing (rubber sealed for Mack) $5.76AB197VBP 6306-2VS Pilot Bearing (Viton Sealed) $10.00AB197SVBP 6306-SN Pilot Bearing (Viton Sealed for Mack) $11.25CS106C-939BP 106C-939 Long Shaft $17.67CS106C-1047BP 106C-1047 Long Shaft $13.74CS106C-1094BP 106C-1094 Long Shaft $15.24CS106C-1529BP 106C-1529 Long Shaft $10.65CSB12815BP 12815 Shaft Bushing (4 per card) $6.06CSF105C-137BP 105C-137 Release Fork $15.92IPS1659 Input Shaft $27.00

Alignment Tools

AT-HT150 1.50 X 10 SPLINE 1.180 pilot $7.98AT-HT175 1.75 X 10 SPLINE 1.180 pilot $7.98AT-HT175A 1.75 X 10 SPLINE .980 pilot $7.98AT-HT175X1 1.75 X 10 SPLINE 1.0 pilot $7.98AT-HT200 2.00 X 10 SPLINE 1.180 pilot $7.98

Installation Kits

AK2468 RT Series Major Install Kit $115.00AK2175 1.75" Minor Install Kit w/Torque Brake $33.65AK2200 2" Minor Install Kit w/Torque Brake $33.65AK2201 2" Minor Install Kit w/2 pc. Hinge Clutch Brake $33.65

Clutch Accessory Items Blister Packed

EZ Rider Clutch PricingMay 1, 2011

1-800-325-6138

8 Piece 16 Piece 32 Piece 48 PieceLoad Torque Spg Prepaid Prepaid Prepaid Prepaid

14" EZ UnitsEZ108034-61B 14 X 2 3600 1250 8 335.72$ 319.73$ 301.11$ 284.30$ EZ108034-82B 14 X 2 3600 1150 8 320.56$ 299.49$ 282.50$ 265.69$ EZ108035-82B 14 X 1.75 3600 1150 8 320.56$ 299.49$ 282.50$ 265.69$ EZ108050-59B 14 X 2 3600 1400 8 376.43$ 358.51$ 316.56$ 299.74$ EZ108050-69B 14 X 2 3600 1400 8 376.43$ 358.51$ 316.56$ 299.74$ EZ108063-59A 14 X 1.75 3600 1400 8 376.43$ 358.51$ 316.56$ 299.74$

15" EZ UnitsEZ208391-74B 15.5 X 2 3600 1650 10 489.46$ 466.15$ 435.75$ 419.51$ EZ208391-77B 15.5 X 2 3600 1250 8 430.31$ 409.82$ 383.96$ 367.15$ EZ208391-78B 15.5 X 2 4000 1450 10 489.46$ 466.14$ 435.75$ 418.94$ EZ208391-81B 15.5 X 2 3600 1400 8 434.70$ 414.00$ 383.95$ 367.15$ EZ208391-82B 15.5 X 2 4000 1400 8 430.31$ 409.82$ 383.95$ 367.15$ EZ208391-93B 15.5 X 2 4000 1860 10 493.46$ 470.15$ 439.06$ 422.26$ EZ208391-93H 15.5 X 2 4000 2050 10 529.46$ 507.42$ 477.61$ 460.79$ EZ208925-82B 15.5 X 2 3600 1700 7 511.42$ 487.07$ 455.00$ 438.18$ EZ208925-82H 15.5 X 2 4000 2050 7 555.42$ 528.98$ 493.53$ 476.73$ EZ208935-51 15.5 X 2 3600 1700 9 513.42$ 489.07$ 457.00$ 440.18$ EZ208935-51H 15.5 X 2 4000 1860 9 557.42$ 530.98$ 495.53$ 478.73$

Medium Duty ApplicationEZ107237-4CB 14 X 1.75 2800 900 8 434.12$ 413.46$ 387.30$ 370.50$ EZ107237-8CB 14 X 1.75 2800 900 8 416.53$ 396.70$ 371.88$ 355.08$ EZ107683-4CB 14 X 1.75 3200 680 8 274.26$ 261.21$ 247.29$ 230.64$ EZ107683-5CB 14 X 1.75 3600 605 8 265.46$ 252.82$ 240.71$ 222.77$ EZ107686-2CB 14 X 2 2800 900 8 416.53$ 396.70$ 371.88$ 355.08$ EZ107686-4CB 14 X 2 2800 900 8 434.12$ 413.46$ 387.30$ 370.50$

Standard Duty107034-61B 14 X 2 3600 1200 8 275.06$ 262.45$ 257.26$ 252.07$ 107034-82B 14 X 2 3600 1150 8 256.44$ 244.23$ 239.08$ 233.93$ 107035-82B 14 X 1.75 3600 1150 8 256.44$ 244.23$ 239.08$ 233.93$ 107050-59B 14 X 2 3600 1400 8 289.29$ 275.54$ 269.80$ 264.06$ 107050-69B 14 X 2 3600 1400 8 289.29$ 275.54$ 269.80$ 264.06$ 107063-59A 14 X 1.75 3600 1400 8 291.62$ 277.74$ 272.47$ 267.19$ 107390-77 15.5 X 1.75 3600 1250 8 363.33$ 346.03$ 343.54$ 341.04$ 107390-80 15.5 X 1.75 3600 1400 8 370.45$ 352.81$ 348.51$ 340.87$ 107391-74B 15.5 X 2 3600 1650 10 358.26$ 341.23$ 326.63$ 312.04$ 107391-77B 15.5 X 2 3600 1250 8 363.33$ 346.03$ 343.54$ 341.04$ 107391-78B 15.5 X 2 4000 1450 10 402.87$ 383.70$ 378.45$ 373.21$ 107391-81B 15.5 X 2 3600 1400 8 325.29$ 309.81$ 305.80$ 301.78$ 107391-82B 15.5 X 2 4000 1400 8 370.45$ 352.81$ 348.51$ 340.87$ 107391-93B 15.5 X 2 4000 1860 10 408.12$ 388.68$ 373.02$ 357.37$ 107925-82B 15.5 X 2 3600 1650 7 423.12$ 402.98$ 387.00$ 371.00$ 107935-51 15.5 X 2 3600 1650 9 423.12$ 402.98$ 387.00$ 371.00$

Proudly Manufactured and Assembled in the USAAbove prices include freight within the 48 contiguous statesPrices shown are based on a single shipment to one locationAdd $18.00 per unit for door to door to CanadaMay mix or match to achieve quantity discountIron based buttons may be substituted for ceramic on all E-Z Rider units at no additional charge

May 1, 2011

Replaces CUMMINS PriceAF3021660 CUMMINS 855 - 15" FLAT 10 Spring 215.00$ AF3071535 CUMMINS 855/N14 - 15" FLAT 7 Spring 220.00$ AF3016495 CUMMINS 855 - 14" POT 8 Spring 205.00$ AF3042787 CUMMINS L10/M11 - 14" POT 8 Spring 220.00$ AF3071615 CUMMINS L10/M11 - 15" FLAT 7 Spring 225.00$ AF3921263 CUMMINS 5.9L - 14" FLAT 8 Spring 145.00$

Replaces CATERPILLARAF1265875 CAT. 3116/3126 - 14" FLAT 8 Spring 150.00$ AF9Y9311 CAT. 3208 - 14" FLAT 8 Spring 186.00$ AF4P4797 CAT. 3406 - 15" FLAT 7 Spring 238.00$

Replaces NAVISTARAF1810855C93 NAVISTAR DT466 - 14" FLAT 8 Spring 135.00$ AF1821915C91 NAVISTAR DT466E - 14" FLAT 8 Spring 145.00$ AF1818214C91 NAVISTAR 7.3 444E - 14"FLAT 8 Spring 145.00$ AF1809144C91 NAVISTAR 6.9/7.3 - 14" FLAT 8 Spring 150.00$

Replaces MACKAF530GB3142 MACK 675/676 15" FLAT 9 S i 195 00$

Heavy Duty Flywheels14" and 15.5"

Freight PrepaidOn 8 pieces

Mix or match

AF530GB3142 MACK 675/676 - 15" FLAT 9 Spring 195.00$ AF530GB3145BM MACK E-7 - 15" FLAT METRIC 9 Spring 195.00$ AF530GB3170 MACK E-7 - E-TECH SERIES 9 Spring 225.00$

Replaces FORDAFE7HZ6375A FORD 6.6/7.8 - 14" FLAT 8 Spring 225.00$

Replaces DETROITAF23509709 DETROIT SERIES 60 - 15" FLAT 7 Spring 225.00$ AF8922126 DETROTI 8.2 - 14"FLAT 8 Spring 185.00$

Heavy Duty Flywheels14" and 15.5"

ACE MFG & PARTS CO. - 300 RAMSEY - SULLIVAN, MO 63080Toll Free 800.325.6138 Phone 573.468.4181 Fax 573.468.5584

www.ace-mfg.com

ALL MANUFACTURERS NAMES, NUMBERS AND DESCRIPTIONS ARE USED FOR REFERENCE PURPOSES ONLY. ACE MANUFACTURING ASSUMES NO RESPONSIBILITY OR LIABILITY DUE TO ERRORS THAT MAY APPEAR IN THE TEXT OF THIS PRICE LIST/CATALOG.

IT WILL BE THE INSTALLERS RESPONSIBILITY TO MAKE SURE THE PROPER APPLICATION IS USED.

Freight PrepaidOn 8 pieces

Mix or match

Flywheel Gauge This gauge is for measuring the flywheel after it has been resurfaced to ensure proper clutch operation and longev‐ity. The gauge is designed to measure three dimensions:

1. Flywheel Mounting Bolt Clearance With the flywheel mounting bolts installed, place on the friction surface of the flywheel with the 5/16” step over the flywheel mounting bolts. S e e Fig. 1 ) If the 5/16” step contacts the head of t h e mounting bolts, the flywheel is too thin and con tact will occur between the clutch disc and mounting bolts. Refer to the OEM to make sure the correct mounting bolts and washers are in‐ stalled before replacing the flywheel. 2. Clutch Centering Lip Place gauge on end contacting flywheel by clutch mounting hole with 3/16” step over the clutch centering lip. (See Fig. 2) If the clutch centering lip contacts gauge, the lip is too tall and will not allow clutch to properly mount to flywheel. 3. Flywheel Depth (Pot Style) Place gauge on end with the 2.937 step on the clutch mounting surface. (See Fig. 3) If the fly‐ wheel is not 2.937 deep, the clutch will not oper‐ ate correctly.

Fig. 3

Fig. 2

Fig. 1

Kit Contains:

•Flywheel Gauge •Clutch Alignment Pins •Disc Alignment Shaft •Shaft Removal Tool •Clutch Adjustment Gauge

‘An Innovative Leader in Clutch Technology’

Ace has been a manufacturer and distributor of heavy duty clutches and clutch compo‐nents for over 40 years. Our 118,000 square foot facility is located in Sullivan, Missouri— just 60 miles west of St. Louis. Ace has a heavy duty clutch for nearly every over‐the‐road tractor hauling in America today, and for many popular vehicles produced in other coun‐tries. With several patents of our own, Ace has improved on many original equipment components and is known throughout the industry as an innovative leader in the heavy duty clutch marketplace.

What we offer at Ace Heavy duty clutches, flywheels, and clutch accessories

State of the art assembly—Unlike the competition, every Ace clutch unit is

assembled in the USA

Warranty—All Ace clutch units offer 12 months and unlimited warranty

against defects in material and workmanship

Training, fieldwork, and clinics provided free of charge

Technical assistance available by calling toll free 18003256138

Ace Manufacturing & Parts Company 300 Ramsey Street, Sullivan, MO 63080 Ph. (573)468‐4181 Fax (573)468‐4497

Once clutch is installed to the flywheel and the other mounting bolts are installed, remove pins and install the last two mounting bolts. Tighten to proper torque. Once the clutch is properly bolted to the fly‐wheel and the shipping blocks have been removed, in‐stall T‐handle in the end of the disc alignment shaft and remove from clutch assembly. (See Fig. 9)

Disc Alignment Shaft

This Shaft is to aid in proper alignment of the clutch disc and clutch assembly at installation.

Place the alignment shaft in the pilot bearing and install correct clutch disc orientated the proper way. (See Fig. 4‐5) Place the center plate in flywheel housing, making sure a lug is between the clutch alignment pins. (See Fig. 6‐7) Install remaining clutch disc (s) orientated the proper way. Install clutch cover assembly over alignment shaft, utilizing clutch alignment pins, installing the center plate in the clutch cover. (See Fig. 8)

Clutch Adjustment Gauge

This gauge is for measuring the dimensions between the clutch release bearing and the clutch brake (1/2”), as well as the dimension between the clutch fork and release bearing wear pads (1/8”), to insure proper clutch adjustment.

Clutch Alignment Pins These Pins are to aid in the installation of the clutch cover assembly to the flywheel. Install these pins in the top two clutch mounting holes in the flywheel completely.

Fig. 9

Fig. 8

Fig. 7

Fig. 6

Fig. 5

Fig. 4 Shaft Removal Tool

EZ208391-74B 15.5” x 2 Ceramic 4 Paddle

10 Spring 1650 Torque

www.ace-mfg.com

E-Z RIDER® HEAVY DUTY CLUTCHES

ACE MANUFACTURING &

PARTS CO.

300 Ramsey Street

Sullivan, MO 63080

Toll Free (800)325-6138

Main (573)468-4181

Fax (573)468-5584

Con tac ts :

Ron Ruff, Sales Manager Email: [email protected] Steve Russom, Inside Sales Email: [email protected] John Muncey, Outside Sales Email: [email protected] Joe Hoffner, Outside Sales Email: [email protected] Robbin Kremer, Marketing Specialist Email: [email protected] Barb Reed, Customer Service Email: [email protected]

ISO 9001:2000 Certification

FOR ALL MEDIUM & HEAVY DUTY VEHICLES

VS.

Replacement Stamped Steel Clutches

15.5” E-Z RIDER®

E-Z RIDER® HEAVY DUTY CLUTCHES

Superb OEM Quality Patented Design Reduced Pedal Effort Exceeds OEM Requirements Cryogenically Treated Springs

Smoother Shifting E-Z Adjust Priced Competitively 1 Year Unlimited Mile Warranty Toll Free Tech Hotline

14” E-Z RIDER®

EZ108050-59B Ceramic 4 Paddle 8 Spring 1400 Torque

EZ108034-82B Organic 8 Spring 1150 Torque


EZ208391-93h Ceramic Full Circle 10 Spring 1860 Torque



EZ208925-82H Ceramic 6 Paddle 7 Spring 2050 Torque

EZ208935-51 Ceramic 4 Paddle 9 Spring 1650 Torque

EZ208935-51H Ceramic 6 Paddle 9 Spring 1860 Torque

Clutch Accessory Items

AK2468 Major Install Kit

AK2200 2” Minor Intall Kit

B201 2” Quick Change Hinge Brake

EZ107237-8CB

14” & 15½” Heavy Duty Flywheels

Replaces CUMMINS

AF3021660 855 - 15” Flat w/ 10 Spring Clutch Disc - AF3071535 855 / N14 - 15” Flat w/ 7 Spring Clutch Disc - AF3016495 855 - 14” Cup w/ 8 Spring Clutch Disc - AF3042787 L10 / M11 - 14” Cup w/ 8 Spring Clutch Disc - AF3071615 L10 / M11 - 15” Flat w/ 7 Spring Clutch Disc - AF3921263 5.9L - 14” Flat w/ 8 Spring Clutch Disc -

Replaces CATERPILLAR

AF1265875 3116/3126 - 14” Flat - AF9Y9311 3208 - 14” Flat w/ 8 Spring Clutch Disc - AF4P4797 3406 - 15” Flat w/ 7 Spring Clutch Disc -

Replaces NAVISTAR

AF1810855C93 DT466 - 14” Flat w/ 8 Spring Clutch Disc - AF1821915C91 DT466E - 14” Flat w/ 8 Spring Clutch Disc - AF1818214C91 7.3 444E - 14” Flat w/ 8 Spring Clutch Disc - AF1809144C91 6.9 / 7.3 - 14” Flywheel w/ 8 Spring Clutch Disc -

Replaces MACK

AF530GB3142 675 / 676 - 15” Flat w/ 9 Spring Clutch Disc - AF530GB3145BM E-7 - 15” Flat Metric w/ 9 Spring Clutch Disc - AF530GB3170 E-7 - E-Tech Series -

Replaces FORD AFE7HZ6375A 6.6 / 7.8 - 14” Flat w/ 8 Spring Clutch Disc -

Replaces DETROIT

AF23509709 SERIES 60 - 15” Flat w/ 7 Spring Clutch Disc - AF8922126 8.2 - 14” Flat w/ 8 Spring Clutch Disc -

ACE MFG & PARTS CO. - 300 RAMSEY - SULLIVAN, MO 63080

Toll Free 800.325.6138 Phone 573.468.4181 Fax 573.468.5584 www.ace-mfg.com

ALL MANUFACTURERS NAMES, NUMBERS AND DESCRIPTIONS ARE USED FOR REFERENCE PURPOSES ONLY.

ACE MANUFACTURING ASSUMES NO RESPONSIBILITY OR LIABILITY DUE TO ERRORS THAT MAY APPEAR IN THE TEXT OF THIS PRICE LIST/CATALOG. IT WILL BE THE INSTALLERS RESPONSIBILITY TO MAKE SURE THE PROPER APPLICATION IS USED.

Recommended Openings

Tech & Installation Tips

The E-Z RIDER® clutch is pre-adjusted at the factory. Therefore, no adjustment should be required at the time of installation. However, if the flywheel has been reground and/or the transmission flange is worn, you may need to use a fiber spacer in conjunction with the new clutch brake you are installing with the clutch. On vehicles with this type of wear, the common complaint at time of installation is “can’t get the clutch brake to squeeze”. The solution could be to use the 1/8” fiber brake washer. Or, you may need to replace the flywheel. Before deciding that, however, we suggest you install the spacer to see if that solves the problem. One is included with this clutch for that purpose. If you do not need it, discard or save for future installations. To use the spacer, slide the fiber washer onto the input shaft next to the transmission before the clutch brake itself is put on. Then install the clutch and set the linkage per your usual procedure. (see schematic 1) If the clutch and the transmission are already installed without the spacer and you are having release prob-lems, it may be possible to install the spacer without removing the clutch and clutch brake. Cut a “V” shape on the fiber so it can be twisted and slipped onto the input shaft from the side. Be sure to cut the bottom of the “V” smaller than the O.D. of the input shaft so it won’t fall off during operation. (see schematic 2) You should now be able to twist the fiber and fit it over the input shaft between the clutch brake and the trans-mission flange. You can now proceed to reset the clearance between the bearing lid and clutch brake at 1/2” to 9/16” with the internal clutch adjuster.

Does your new clutch need a clutch brake spacer?Does your new clutch need a clutch brake spacer?

Clutch Brake

Input Shaft

Transmission Flange

Clutch Release Bearing

Flyw

heel

Sid

e

Spacer

Schematic 1

Schematic 2

Insert Spacer Here

O.D.

I.D.

For 2” Shafts O.D. 2.0” I.D. 1.5”

For 1 3/4” Shafts

O.D. 1.75” I.D. 1.25”

Tech Hotline 1.800.325.6138 Mon - Fri

7am - 5pm CST

Ace Manufacturing & Parts Co. 300 Ramsey Street, Sullivan, Missouri 63080 Ph. 573.468.4181 Fax 573.468.5584

This clutch installation kit includes the following:

Clutch Housing GasketFront Bearing Cover GasketInner Retaining Ring Outer Retaining RingFront Bearing Cover2” Torque Brake

Shift Lever Housing GasketBearing w/Snap RingPilot BearingCross Shaft Bushings Standard Release Yoke2” - 10 Spline Input Shaft

Made in the USA

AK2468CLUTCH INSTALLATION KIT

Call Toll Free1-800-325-6138

(1) CSF105C137 Fork(1) A240 2” Brake(4) CSB12815 Bushings

AK2200OUR “BASIC” CLUTCH INSTALLATION KIT

Includes:

Ace Manufacturing & Parts Co. 300 Ramsey Street, Sullivan, Missouri 63080 Ph. 573.468.4181 Fax 573.468.5584Ace-Mfg.com

(1) CSF105C137 Fork(1) B201 2” 2 Piece Clutch Brake(4) CSB12815 Bushings


With 2 Pc. Clutch Brake

Includes:


(1) CSF105C137 Fork(1) A240 2” Brake(4) CSB12815 Bushings


Includes:

$33.65


(1) CSF105C137 Fork(1) B201 2” 2 Piece Clutch Brake(4) CSB12815 Bushings


With 2 Pc. Clutch Brake

$33.65

Includes:

Clutch InstallationTool Kit

Part No. ATK-200

$95.00

Kit Contains

Clutch Adjustment Gauge,

Disc Alignment Shaft, Clutch

Alignment Pins, Shaft Removal

Tool, Flywheel Gauge



Visit us at www.Ace-Mfg.com

Heavy Duty Clutches, Flywheels & Accessories 300 Ramsey Street Sullivan, MO 63080 Ph. (573)468-4181 Fax (573)468-5584

→ For 45 years, Ace Manufacturing & Parts Company has been supplying clutch as-

semblies and components worldwide.

→ Reduced cost: E-Z Rider clutches are priced nearly $100 lower than the most

popular O.E.M. clutch.

→ No cores to handle: Because we are the manufacturer, we supply all new parts

and assemblies made and assembled at our plant in Sullivan, Missouri.

→ Shipping Policy: We strive to ship all orders entered before 1:00 PM the same day.

→ Freight Policy: 4, 8 or 16 clutches, mixed or matched, will be shipped freight pre-

paid or an allowance can be made for customer arranged pick-up.

→ Mack Application: As part of the E-Z Rider series clutch line, we offer EZ108935-51

and the heavier version EZ108935-51H. New 9 spring clutches have typically been

reserved by the dealers.

→ Warranty: For 12 Months and unlimited mileage, Ace clutches are warranted to be

free of defects in material and workmanship.

Why choose Ace E-Z Rider?

Visit us at www.Ace-Mfg.com

→ Friction Material: Ace Manufacturing is the only clutch manufacturer in the U.S.A.

that produces the friction material used in their clutches.

→ Fiber Brake Spacer: Shipped free of charge in every new Ace clutch. The spacer

is essential to achieving brake squeeze where the flywheel has been resurfaced.

→ Training and Fieldwork: As an added service, Ace will provide training and trouble-

shooting free of charge.

→ Dual Adjust: Ace clutches incorporate E-Z adjust feature, as well as the manual ad-

just.

→ Disc Springs: Every Ace clutch is shipped with disc that have premium, chrome sili-

con, valve quality, and cryogenically treated springs. A patented process exclusive

to Ace.

→ State-of-the-Art Assembly: Unlike the competition, every Ace clutch is shipped as a

“serialized” matched unit. Our 15.5” units go through a series of lasers and load

cells, where measurements are taken and digitally recorded to the specific serial

number assigned.

→ Ace E-Z Rider series clutch units are used by many nationwide carries, such as

Yellow, Roadway, National Lease, U.P.S., Pam Transport, Waste Management,

Celedon, and numerous other carriers.

HEAVY DUTY QUICK REFERENCE

ACE EATON MERITOR HALDEX MID-AMERICA UNIQUE

EZ108035-82B R141451 N10803582 127400DS M108035-6A5

EZ108063-59A N10806359 127400DSCB M108063-6J5

EZ108034-82B 108034-82B R140151 N10803482 127390DS M108034-6A5

EZ108034-61B 108034-61B R141101 N10803461 M108034-6F5

EZ108050-69B N10805059 MU127390DSCB M108050-6J5

EZ108050-59B 108050-59 R140401 N10805059 MU127390DSCB M108050-6J5

108034-59

EZ208391-77B 108391-77B R150155 127597DS M108391-6A5

EZ208391-82B 108391-82B R150155 N10839182 127597DS M108391-6A5

EZ208391-81B 108391-81B M151406 N10839181 127597DSCB M1083916G5

EZ208391-82B 108391-82B R150155 N108391-82 127597DS M108391-6A5

EZ208391-74B 108391-74B M151406 N10839174 MU129698SB10 M108391-5-G5

EZ208925-82B 108925-82B R152705 N10892582 MU129698SB7 M10892511G5

EZ208935-51 108935-51 R151725 N10893551 MU129698SB9 M1089259G5

EZ208935-51H 108935-94 R153726 N10893594 MU15569812SB9 M1089259G5

EZ208925-82H 108925-1O R151706 N10893515 MU15569812SB7 M10892514W5

108925-20

108925-25

EZ20839193B 108391-93B R151405 N1089355A5 MU155698SB10

EZ208391-93H R151406 N10893593 MU15569812SB10 M1083915W5

STOP! READ CAREFULLY BEFORE INSTALLING CLUTCH

This clutch must be installed by a qualified installer. Improper installation or failure to replace or resurface the flywheel, or to replace the pilot bearing, clutch brake or other worn drive train components may cause poor clutch release or early failure and void the manufacturer’s warranty. Before you install this clutch, you must measure the flywheel opening to determine if you have the correct clutch for your application.

Use one of these models only

E-Z RIDER® Clutch choices EZ108391-81B EZ108390-80 EZ108-391-77B EZ108391-81B EZ108391-82B Standard Clutch choices 107391-77 107390-80 107391-77B 107391-81B 107391-82B

E-Z RIDER® Clutch choices EZ208391-74B EZ208391-78B EZ208391-93B EZ208391-93H Standard Clutch choices 107391-74B 107391-78B 107391-93B

E-Z RIDER® Clutch choices EZ208925-82B EZ208925-82H EZ208935-51 Mack Only EZ208935-51H Mack Only Standard Clutch choices 107925-82B 107935-51 Mack Only


8 SPRING DISC

10 SPRING DISC

7 & 9 SPRING DISC

CHOOSING THE WRONG CLUTCH FOR YOUR APPLICATION VOIDS YOUR WARRANTY!


Your flywheel bore size Must Use

Insert #1001 January 2010

E-Z RIDER® IS A REGISTERED TRADEMARK OF ACE FMG. & PARTS CO., INC. SULLIVAN, MO. USA

7.25 BORE

7”

8.562 BORE

8.5”

9.750 BORE

10”

This clutch was pre-adjusted at the factory. Therefore, no adjustment should be required at the time of installation. However, if the flywheel has been reground and/or the transmission flange is worn, you may need to use a fiber spacer in conjunction with the new clutch brake you are installing with the clutch. On vehicles with this type of wear, the common complaint at time of installation is “can’t get the clutch brake to squeeze”. The solution could be to use the 1/8” fiber brake washer. Or, you may need to replace the flywheel. Before deciding that, however, we suggest you install the spacer to see if that solves the problem. One is included with this clutch for that purpose. If you do not need it, discard or save for future installa-tions. To use the spacer, slide the fiber washer onto the input shaft next to the transmission before the clutch brake itself is put on. Then install the clutch and set the linkage per your usual procedure. (see schematic 1) If the clutch and the transmission are already installed without the spacer and you are having release problems, it may be possible to install the spacer without removing the clutch and clutch brake. Cut a “V” shape on the fiber so it can be twisted and slipped onto the input shaft from the side. Be sure to cut the bottom of the “V” smaller than the O.D. of the input shaft so it won’t fall off during operation. (see schematic 2) You should now be able to twist the fiber and fit it over the input shaft between the clutch brake and the transmission flange. You can now proceed to reset the clearance between the bearing lid and clutch brake at 1/2” to 9/16” with the internal clutch adjuster.

Does your new clutch need a clutch brake spacer?Does your new clutch need a clutch brake spacer?

Clutch Brake

Input Shaft

Transmission Flange

Clutch Release Bearing

Flyw

heel

Sid

e

Spacer

Schematic 1

Schematic 2

1 3/4” Fiber Part No. A153

2” Fiber Part No. A148

Insert Spacer Here Recommended

Openings

O.D.

I.D.

For 2” Shafts O.D. 2.0” I.D. 1.5”

For 1 3/4” Shafts O.D. 1.75” I.D. 1.25”

GENERAL INSTALLATION GUIDELINES For 14” and 15.5” Two-plate Clutches

1. (14” & 15.5’) Check condition of flywheel. If it is cracked or warped, resurface or replace flywheel. Surface must be smooth or premature clutch failure can occur. Flywheel depth must be 2.937” for 14” two-plate clutches. The 15.5” clutch uses a flat flywheel. REMEMBER: Machining the flywheel past the .060” recom-mended moves the pressure plate away from the transmission. In this event, install a fiber spacer (provided) on the pilot shaft between the clutch brake and the transmission. The release yoke in the bell housing may not align properly with the pressure plate release bearing housing. Linkage adjustment may be required.

2. (14” & 15.5 “) Inspect and dial-indicate the mating surface of engine flywheel housing and clutch bell housing for alignment and also check flywheel run out. CAUTION: If misalignment is greater than limits recommended, this will cause poor clutch release, rapid wear on transmission pilot shaft and destruction of the clutch disc. Excessive flywheel run out may cause severe vibration in vehicle drive line.

3. (14” & 15.5 “) A new pilot bearing must be used. Before installing pilot bearing into flywheel, check freedom of movement on transmission pilot shaft.

4. (14” Only) Drive pins in the flywheel must be replaced. Check and be sure drive pin heads are square with the flywheel friction surface. (If drive pins are not replaced, assume that they are not square. The constant pound-ing of the center plate may have changed the position of the drive pins in the flywheel. Play it safe—Replace them all!)

5. (14” Only) After the drive pins are installed and properly aligned, position the center plate onto the drive pins and check the clearance with a feeler gauge. Clearance should be .006” to .010” and be measured from the same side of the drive pin at each location. The center plate should move up and down freely on the pins.

6. (14” Only) Install front clutch disc, center plate and rear disc as marked. 7. (14” Only) Insert alignment shaft through both clutch discs making sure it enters the pilot bearing. (NOTE: If an

old pilot shaft with worn splines is used to align clutch disc, transmission pilot shaft may damage clutch hubs during installation of transmission.)

8. (14” Only) Position cover assembly onto the pilot shaft and guide towards flywheel mounting surface, making sure the cover fits into the flywheel pilot. Start cap screws.

9. (15.5” Only) Insert alignment shaft through bearing housing. Install rear disc, center plate, and front disc on alignment shaft. Move clutch housing towards flywheel making sure cover fits into flywheel pilot.

10. (14” & 15.5”) Install the cap screws that fasten the clutch housing on the flywheel. Tighten the cap screws to the specified torque and the sequence specified by the manufacturer of the vehicle or transmission. Cap screws should be Class 5 or greater.

11. (14” & 15.5”) Examine transmission pilot shaft for wear and replace if necessary. (Worn splines on pilot shaft will cause clutch to release improperly and may cause splined hubs in clutch disc to break out.)

12. (14” & 15.5”) Inspect release bearing yoke and both cross shaft bushings in bell housing and replace if worn. (NOTE: For proper clutch release, release bearing housing on cover must ‘squeeze’ clutch brake during clutch disengagement. Worn parts in bell housing may prevent full movement of release bearing during operation of vehicle.)

13. (14” & 15.5”) If clutch brake is to be used, place on transmission pilot shaft. 14. (14” & 15.5”) Rotate release bearing housing on cover assembly until flat section is on top. (NOTE: Bell hous-

ing cross shaft on some vehicles may be below center. This requires the flat section on release bearing to be in down position.) Note position on clutch when being removed.

15. (14” & 15.5”) Using extreme caution, guide transmission through cover and disc assembly, rotating bell housing shaft so that release yoke fingers are clear of the pads on the release bearing assembly. (warning: Transmis-sion must not hang or be forced into the clutch. This can warp the clutch disc and prevent the clutch from re-leasing.)

16. (14” & 15.5”) Start bell housing cap screws and tighten progressively to the torque recommended by the vehicle manufacturer.

17. (14” & 15.5”) Release bearing has been pre-packed with grease from the factory. 18. (14” & 15.5”) Install clutch linkage. See “Clutch Adjustment Procedure”.

CLUTCH ADJUSTMENT PROCEDURE

NOTE: Clutches are adjusted at the factory to original equipment specifications and should require very little internal adjustment to achieve proper release and engagement. The clutch must not be adjusted to accommodate thin or worn flywheels, or worn linkage, yoke and/or cross shaft bushings, or to accommodate other drive train deficiencies. Adjustment for such purposes will either cause the clutch to not function properly or will cause early clutch failure and will be apparent on factory inspection of warranty claims, thereby voiding the manufacturer warranty.

THIS PROCEDURE COVERS BOTH 14” AND 15-1/2” CLUTCHES

STEP #1 After clutch installation, check the clearance between the yoke tips and wear pads on bearing housing for 1/8” clearance. This determines pedal free play. (See illustration) Adjust the clutch linkage to increase or decrease the yoke-to-bearing clearance. NEVER USE THE INTERNAL CLUTCH ADJUSTMENT FOR THIS PURPOSE. STEP #2 Check for proper clutch brake and bearing gap of 1/2” to 9/16”. If the gap is not within these tolerances, add the spacer brake if needed and check clearance again. If the clutch does need adjusting, push & turn adjust nut collar and set the clearance between the bearing and clutch brake at 1/2” to 9/16”. THIS DIMENSION IS CRITICAL. DO NOT VARY—EITHER OVER OR UNDER THESE DIMENSIONS—UNDER ANY CIR-CUMSTANCES. Over adjusting either way will cause the clutch to slip or not release. Use the internal adjustment on the clutch to move the bearing. Turn adjuster clockwise to move bearing towards transmission (to decrease clearance) or counter clockwise to move the bearing towards the engine (to increase clearance). If internal adjustment exceeds 4 notches either way the clutch may not release or may slip. Put tension on the linkage to be sure bearing is stretched and no movement towards the engine is noticed. Measure clutch brake and bearing gap with 1/2” - 9/16” gauge. (See Illustration) REMINDER: The bearing must move a minimum of 1/2” or clutch will not release. Eliminate lost motion before checking for 1/2” move-ment. Lost motion is generally caused by loose or worn linkage, or worn yoke or cross shaft bushings. STEP #3 If internal clutch adjustment was made, re-verify the 1/8” clearance between the yoke tips and wear pads on bearing housing shown in Step #1 above. If necessary, re-align linkage to obtain proper clearance. (See Illustration) STEP #4 Re-verify the clutch brake squeeze by inserting .010 feeler gauge between bearing and clutch brake, then depressing the pedal to end of stroke. The feeler must be tightly clamped between the bearing and the clutch brake. (See Illustration) This verifies the contact of the bearing to the clutch brake. The clutch brake will be squeezed if the total pedal stroke slightly exceeds the movement required to move the yoke/fork 5/8” to 11/16” (the combined total of the 1/8” clearance between yoke tips and wear pads and the 1/2” - 9/16” brake squeeze gap. IN THE EVENT THE BRAKE IS NOT BEING SQUEEZED, DO NOT CHANGE THE 1/2” - 9/16” GAP FOR THE CLUTCH BRAKE, OR THE 1/8” CLEARANCE FOR THE BEARING HOUSING—CONSULT THE VEHICLE MANUFACTURER SER-VICE MANUAL. In analyzing the reasons for the brake not being squeezed, other things to check for are: A. Worn linkage components or yoke and cross shaft bushings. If necessary, replace those components. B. Improper linkage assembly. Verify that linkage is assembled in the correct hole locations. C. Pedal stroke. To adjust, raise the upper and/or lower the lower pedal stops.

CLUTCH ADJUSTMENT PROCEDURE (con’t.)

NOTE: MAXIMUM BRAKE SQUEEZE (IN CAB OF TRUCK) SHOULD NOT EXCEED 1” FROM THE END OF PEDAL STROKE. IF IT DOES, IT CAN BE ADJUSTED BY: A. Changing pedal stops in cab to reduce total pedal stroke. B. Increasing 1/8” yoke-to-bearing setting to lower squeeze. (This will increase free-pedal travel.) STEP #5 Once the external parts are in tune with the clutch, record the measured amount of free-pedal movement in the vehicle log. This is the normal (standard) pedal travel for this vehicle. Then, if and when the clutch again needs adjustment, it should be adjusted back to this standard. Example: If pedal travel standard is 2”, the clutch may need adjustment when wear has reduced it to about 1” of travel. INSTALLER SHOULD CAREFULLY CHECK TO VERIFY THAT THERE IS 1/8” OF FREE TRAVEL BETWEEN THE YOKE AND THE WEAR PADS AND A MINIMUM OF 1/2” TO 9/16” OF SPACE BETWEEN THE BEARING AND THE CLUTCH BRAKE.

Maintenance Tips

IT IS IMPORTANT TO NOTE THAT THESE ARE GENERAL GUIDELINES ONLY AND THAT THE INSTALLER SHOULD ALWAYS REFER TO THE VEHICLE MAINTENANCE MANUAL FOR SPECIFIC DETAILS. 1. The clutch should be lubricated after each adjustment.

2. Only high temperature grease should be used for clutch bearing hous-

ing and linkage lubrication. Do not use chassis lubricant for clutch lu-

brication. Refer to the vehicle maintenance manual for lubricant speci-

fications.

3. Lubricate the clutch release bearing each time the chassis is lubricated.

4. When lubricating the clutch, apply lubricant to each fitting on the clutch

housing.

5. Every point in the clutch linkage must be lubricated in addition to the

clutch housing.

6. Adjust the clutch before the pedal clearance has disappeared. Failure

to do so will result in slippage and adjustment afterwards may not be

effective.

7. If the clutch is hydraulically assisted, make sure the slave and master

cylinders are functioning properly.

You must have a minimum of 5/16” distance from the friction surface

(face) of your flywheel to the top of the bolthead that holds the flywheel

to the crankshaft. If it is less than 5/16”, you need a

NEW flywheel!

Tech Tip

ACE Manufacturing Introduces

QUICK CHANGE HINGE BRAKE

Information Technology Solutions

ACE Manufactur ing & Par ts

Company, Inc .

300 Ramsey Street

Sullivan, MO 63080

Toll Free (800)325-6138

Main (573)468-4181

Fax (573)468-5584

Contacts Joe Hoffner, Sales Manager Email: [email protected] Steve Russom, Inside Sales Email: [email protected] Dwayne Hoke, Inside Sales Email: [email protected] Warren Wideman, Inside Sales Email: [email protected] Barb Reed, Customer Service Email: [email protected] Robbin Kremer, Marketing Manager Email: [email protected] Jennifer Hoke, Marketing Assistant Email: [email protected]

Cer t i f icat ion:

ISO 9001:2008

What we offer at ACE:

Heavy duty clutch parts and assemblies

Racing clutch parts and assemblies

Powdered metal products

Metal stamping and forming

Friction material bonding

CNC Laser cutting

Engineering

Tooling

Wire EDM

‘An innovative leader in clutch technology’

Patent pending centrifugal assist locking mechanism

Easy multidirectional installation

Fast, one step removal

Rigid design - constructed with medium carbon laminate steel

High quality friction material -withstands heat in high abrasive conditions

Lower unit price. Save money without sacrificing quality!

How Does it Compare?

*Patent Pending

2” (B201)

1.75” (B175)

2” Oversized (B201-500)